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HOMESERVICE MANUALSCHEVROLET1999PICKUP K1500, 5.7 RREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 663 (ENGINE MECHANICAL - 3.8L (ON-VEHICLE))REPAIR INSTRUCTIONSENGINE REPLACEMENTINSTALLATION PROCEDURE
1999 Chevrolet Pickup K1500, 5.7 R

Installation Procedure

1999 Chevrolet Pickup K1500, 5.7 RSECTION Installation Procedure
WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to ENGINE EMISSION NOTICE .
  1. Install the right exhaust manifold, the left exhaust manifold and the exhaust crossover. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.1L) or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) and to EXHAUST MANIFOLD REPLACEMENT - LEFT (3.1L) or EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8L) .
  2. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  3. Install the engine lift brackets.
    NOTE: Refer to FASTENER NOTICE .
  4. Install the bolts and the nuts to the left and the right engine lift bracket.

    Tighten 

    Tighten the bolts and the nuts to 30 N.m (22 lb ft).

  5. Install the generator brace bracket to the right cylinder head.
  6. Install the bolts to the generator brace bracket.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

  7. Install the upper intake manifold or supercharger. Refer to Intake Manifold Replacement - Upper  or to Supercharger Replacement .
  8. Install the EGR valve adapter to the right cylinder head. Refer to REMOVAL (3.8L -- INLET PIPE) .
    Fig 1: Installing Generator Bracket & Bolts
    G01703396Courtesy of GENERAL MOTORS CORP.
  9. Install the bracket to the fuel injector sight shield.
  10. Install the bracket nuts to the fuel injector sight shield.

    Tighten 

    Tighten the nuts to 30 N.m (22 lb ft).

    Fig 2: Installing Fuel Injector Sight Shield Bracket & Nuts
    G01703397Courtesy of GENERAL MOTORS CORP.
  11. Install the A/C compressor bracket and bolts.

    Tighten 

    Tighten the bracket bolts to 50 N.m (37 lb ft).

  12. Install the left and right side engine mount brackets. Refer to Engine Mount Strut Bracket Replacement - Left  and to Engine Mount Strut Bracket Replacement - Right Upper (L36)  or Engine Mount Strut Bracket Replacement - Right Upper (L67) .
  13. Install the ignition control module bracket and the ignition control module. Refer to IGNITION CONTROL MODULE .
  14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) .
    Fig 3: Installing A/C Compressor Bracket & Bolts
    G01703398Courtesy of GENERAL MOTORS CORP.
  15. Install the engine mount bracket and install the bracket bolts to the right side engine mount.
    Fig 4: Installing Right Engine Mount Bracket & Bolts
    G01703399Courtesy of GENERAL MOTORS CORP.
  16. Install the bracket bolts to the left side engine mount.

    Tighten 

    Tighten the bracket bolts to 102 N.m (75 lb ft).

    Fig 5: Installing Left Engine Mount Bracket & Bolts
    G01703400Courtesy of GENERAL MOTORS CORP.
  17. Install the oil indicator tube to the engine. Ensure that the O-ring is in place. Ensure that the oil level indicator tube is fully seated in the engine.

    Tighten 

    Tighten the nut on the oil level indicator tube to 19 N.m (14 lb ft).

  18. Remove the engine from the engine stand.
  19. Install the flywheel. Refer to Engine Flywheel Replacement .
  20. With the aid of an assistant, install the engine to the vehicle.
    Fig 6: Installing Oil Indicator Tube
    G01703401Courtesy of GENERAL MOTORS CORP.
  21. Secure the upper transaxle to the engine with the bolts (2,3,4,5).

    Tighten 

    Tighten the bolts to 75 N.m (55 lb ft).

  22. Remove the engine lifting device.
    Fig 7: Installing Upper Transaxle-To-Engine Bolts
    G01703402Courtesy of GENERAL MOTORS CORP.
  23. Install the A/C compressor to the A/C compressor bracket.

    Tighten 

    Tighten the A/C compressor nuts to 30 N.m (22 lb ft).

  24. Install the heater hoses to the drive belt tensioner. Refer to HEATER HOSE REPLACEMENT - INLET (3.1L) or HEATER HOSE REPLACEMENT - INLET (3.8L) and to HEATER HOSE REPLACEMENT - OUTLET (3.1 L) or HEATER HOSE REPLACEMENT - OUTLET (3.8L) .
  25. Install the radiator outlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.1 L) or RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) .
  26. Install the radiator inlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1 L) or RADIATOR HOSE REPLACEMENT - INLET (3.8L) .
  27. Reposition the engine wiring to the engine.
  28. Connect the upper engine electrical connectors to the following components:
    • The manifold absolute pressure (MAP) sensor
    • The exhaust gas recirculation (EGR) valve
    • The EVAP purge solenoid
    • The idle air control (IAC) valve
    • The throttle position (T/P) sensor
    • The fuel injectors
  29. Install the upper engine wiring harness to the retaining clips.
    Fig 8: Installing A/C Compressor To Bracket
    G01703403Courtesy of GENERAL MOTORS CORP.
  30. Install the power steering pump to the engine.

    Tighten 

    Tighten the power steering bolts to 34 N.m (25 lb ft).

  31. Connect the A/C vacuum hose to the engine.
  32. Install the vacuum booster hose to the engine. Refer to POWER BRAKE BOOSTER CHECK VALVE/HOSE .
  33. Install the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC .
  34. Connect the positive battery cable.

    Tighten 

    Tighten the cable terminal nut to 15 N.m (11 lb ft).

  35. Install the engine mount brackets to the radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
  36. Install the engine mount struts to the engine mount strut brackets. Refer to Engine Mount Strut Replacement - Right  and to Engine Mount Strut Replacement - Left .
    Fig 9: Installing Power Steering Pump
    G01703404Courtesy of GENERAL MOTORS CORP.
  37. Install the water pump pulley.
  38. Install the water pump pulley bolts.

    Tighten 

    Tighten the pulley bolts to 13 N.m (116 lb in).

  39. Install the drive belt.
  40. Install the throttle cable, the cruise control cable and bracket to the throttle body. Refer to
  41. Connect the fuel vapor line.
    Fig 10: Installing Water Pump Pulley & Bolts
    G01703405Courtesy of GENERAL MOTORS CORP.
  42. Connect the fuel lines (1,2) to the fuel rail. Refer to
  43. Install the throttle body air inlet duct and the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY .
  44. Raise the vehicle and remove the transaxle support.
    Fig 11: Fuel Lines
    G01703406Courtesy of GENERAL MOTORS CORP.
  45. Secure the lower transaxle to the engine with a bolt (6) and a stud (1).

    Tighten 

    Tighten the bolt and the stud to 75 N.m (55 lb ft).

  46. Install the engine ground to the transaxle stud.

    Tighten 

    Tighten the engine ground nut to 35 N.m (26 lb ft).

  47. Install the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  48. Reposition and connect the electrical connectors to the following components:
    • The heated oxygen (H02) sensor
    • The knock sensors
    • The oil level sensor
    • The oil pressure sensor
    • The vehicle speed sensor (VSS)
      Fig 12: Installing Lower Transaxle
      G01703407Courtesy of GENERAL MOTORS CORP.
  49. Install the harness retainer on the oil level sensor to the engine.

    Tighten 

    Tighten the retainer bolt to 10 N.m (89 lb in).

  50. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.1L) or CATALYTIC CONVERTER REPLACEMENT (3.8L) .
  51. Install the engine mount lower nuts.

    Tighten 

    Tighten the lower nuts to 78 N.m (58 lb ft).

  52. Install the transaxle brace. Refer to TRANSAXLE BRACE .
  53. Install the engine flywheel-to-torque converter bolts. Refer to
  54. Install the starter motor. Refer to STARTER MOTOR .
  55. Install the torque converter cover. Refer to
  56. Lower the vehicle.
  57. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) .
  58. Install the hood. Refer to HOOD REPLACEMENT .
  59. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  60. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  61. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  62. Inspect for leaks.
  63. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR .
    Fig 13: Installing Engine Mount Lower Nuts
    G01703408Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.